Chemical Production Scheduling Case Study | PlanetTogether

Nova Chemicals, a chemical manufacturer, needed a clearer way to move planning and scheduling data between IBP, Aspen, SAP, and production scheduling. The issue was not a lack of data. It was the time, complexity, and risk created by too many disconnected handoffs.

PlanetTogether APS was evaluated as a way to connect scheduling logic, material planning, and production constraints in one planning process. The goal was to reduce manual scheduling effort, improve raw material visibility, and make production plans easier to update.

Answer Capsule: This chemical APS case study shows how Nova Chemicals addressed planning complexity across IBP, Aspen, SAP, and production scheduling. PlanetTogether APS helped create a more connected workflow for order generation, production sequencing, raw material forecasting, and schedule-based planning decisions.

Planning and Scheduling Complications

Nova Chemicals needed to simplify how planning and scheduling data moved between IBP, Aspen, SAP, and the production schedule. Each system played an important role, but the handoffs between systems created delays, rework risk, and potential data inconsistencies.

In chemical manufacturing, those issues can affect more than the schedule. They can also affect raw material planning, reactor grade sequencing, production timing, and the planner’s ability to respond when demand or supply changes.

Challenges

The scheduling workflow depended on several systems, including Integrated Business Planning (IBP), Aspen, and SAP. These systems supported important planning tasks. However, data still had to move through multiple steps before planners could use it in the production schedule.

• Manual scheduling: Schedulers could change the board without enough constraint logic. This increased the risk of inefficient sequences or scheduling errors.
• Lack of consolidation: Raw material requirements were not managed through one shared planning view. As a result, shortages and planning gaps were harder to see early.
• Forecasting difficulties: Forecasting key materials such as ethylene was harder without a direct connection between the schedule and material requirements.
• Data flow complexity: Data moved through IBP, Aspen, SAP, and scheduling steps. Each handoff increased the risk of delays and inconsistent planning assumptions.

As a result, planners needed a more connected process for production scheduling, raw material forecasting, and schedule updates.

Decision Framework: When Chemical Manufacturers Need APS

Chemical manufacturers should consider APS when planning complexity slows scheduling decisions, material planning, or production changes.

• Use APS when scheduling depends on several systems. If planners move data between IBP, ERP, process modeling, and scheduling tools, APS can help create a more connected planning process.
• Use APS when material forecasts depend on the schedule. If raw material needs change as production timing changes, schedule-driven reporting can reduce planning risk.
• Use APS when sequencing rules matter. If reactor grades, cleanouts, tank capacity, or changeovers affect production timing, finite-capacity scheduling can make plans more realistic.
• Use APS when manual scheduling creates risk. If schedule changes happen without constraint logic, planners may need guardrails that reflect real production limits.

How APS Helped Address the Scheduling Bottlenecks

Nova Chemicals evaluated PlanetTogether APS to create a more structured planning and scheduling workflow. The APS model focused on automated order generation, sequencing rules, material forecasting, and direct schedule-based reporting.

Rather than relying only on manual schedule changes, planners could use APS logic to support more consistent decisions around reactor grades, raw materials, and production timing.

Automated Order Generation

In this workflow, PlanetTogether APS can support automated order generation across a defined planning period. This reduces manual planning effort and gives planners a more consistent view of future production requirements.

Controlled Flexibility

Planners can still make manual changes when needed. However, APS rules can help enforce production sequencing and reactor grade logic, which supports a more realistic schedule.

Reduced Scheduling Gaps

PlanetTogether APS can apply sequencing rules and reactor grade logic to reduce gaps in the production schedule. This gives planners a clearer view of where work can run and where constraints may still exist.

Unified Material Management

The material consumption forecast report gives planners a consolidated view of raw material requirements. This helps the team compare production plans against expected material demand before shortages create schedule risk.

Direct Feed from Scheduling

The forecast report can use data directly from the PlanetTogether schedule. Therefore, raw material requirements stay aligned with current production plans.

Improved Accuracy

A direct link between scheduling and material forecasting reduces the risk of mismatched data. As a result, planners can spot material issues earlier and adjust the production plan with better context.

Streamlined Operations

The automated feed from PlanetTogether keeps the forecast report current as the schedule changes. This reduces manual updates and lowers the risk of planning errors caused by outdated data.

What the APS Workflow Changed

The APS workflow gave Nova Chemicals a more connected way to manage production scheduling, material forecasting, and system data. Instead of relying on disconnected handoffs between IBP, Aspen, SAP, and scheduling, planners could work from one schedule-driven planning process.

This helped reduce the risk of data delays, inconsistent assumptions, and manual planning errors. It also gave the team a clearer way to connect production schedules with raw material requirements.

Chemical APS Case Study FAQs

What problem did Nova Chemicals need to solve?

Nova Chemicals needed to reduce planning complexity between IBP, Aspen, SAP, and production scheduling. The goal was to improve data flow, raw material visibility, and schedule reliability.

How can APS help chemical manufacturers?

APS can help chemical manufacturers model finite capacity, sequencing rules, raw material requirements, and what-if schedule changes in one planning environment.

Why does raw material forecasting matter in chemical scheduling?

Raw material forecasting matters because production timing can change material needs. A schedule-driven forecast helps planners see expected material requirements before shortages affect production.

What is controlled flexibility in APS scheduling?

Controlled flexibility means planners can still adjust the schedule manually while APS logic applies rules for constraints, sequencing, and production feasibility.

When should a chemical manufacturer consider APS?

A chemical manufacturer should consider APS when manual scheduling, disconnected systems, material planning gaps, or sequencing constraints make the production schedule hard to trust.

See Your Chemical Scheduling Workflow in a Live APS Demo

Compare your current manual scheduling, ERP workflow, and material planning process with PlanetTogether APS. In a demo, you can review automated order generation, finite-capacity scheduling, and what-if scheduling.

You can also discuss reactor grades, raw materials, and sequencing rules with the PlanetTogether team.

Request a PlanetTogether APS demo.